Dispensing system for returnable bulk containers
A dispensing system for returnable bulk shipping containers and more particularly to a apparatus and method for selectively emptying the contents of bulk containers which, when emptied, can be returned to the supplier for refilling. The apparatus comprises a hoist having vertical lift capability. A rotator provided on the hoist provides horizontal rotation capability to a container press. A funnel cap is provided with the container press which is configured to replace the cover of the container, thereby retaining any structural integrity afforded by the cover. The funnel cap includes a selectively operable valve. The funnel cap operates in conjunction with a platen which is used to initially support the container in its upright position. The funnel cap and platen are movable away from one another to enable containers to be inserted or removed therefrom. The funnel cap and platen are movable toward one another to enable a container to be engaged and retained therein. The funnel cap and platen exert sufficient force on the container such that during lift and rotation of the container, it will not fall out. Once inverted, the contents of the container will have been gravitationally fed into the funnel. The valve in the funnel may then be selectively operated to dispense discreet quantities of flowable material.
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This application claims the benefit of U.S. Provisional Application No. 60/516,288 filed Nov. 3, 2003.
FIELD OF THE INVENTIONThe invention relates to dispensing systems for returnable bulk shipping containers and more particularly to a apparatus for selectively emptying the contents of bulk containers which, when emptied, can be returned to the supplier for refilling.
BACKGROUND OF THE INVENTIONThere are a number of different types of bulk shipping containers in use today. Some of these containers include:
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- Paper, paperboard or cardboard boxes on pallets made of wood or other materials;
- Smaller boxes, generally of paper, with or without bags or liners inside; and
- Hard bins, for example Ropak™ and Linpac™ brand containers.
Although disposable containers make up a significant proportion of the market, a returnable solution offers both economic and ergonomic advantages. These these markets are showing signs they are ready to convert to returnables, and there is a trend driven by both economic and ergonomic factors.
Containers for bulk fluid or granulated materials require systems for dispensing the materials at the point of use. Presently, containers are emptied by corner or side tear-away cutting, manual dump (of smaller boxes) or are side dumped, which methods do not permit direct flow control of the material. Where flow control is required, the containers must be emptied into metering devices, requiring additional equipment and material handling steps. Furthermore, these methods permit the materials to be exposed to the environment during dumping and may result in dust or residue being generated from the movement of the bulk material.
Some bulk containers include a hopper mechanism or a built-in dispensing port/valve but such devices add to the complexity and cost of the container and can be inconvenient or space-consuming for knock-down or disassemblable returnable containers.
By providing the dispensing mechanism in association with the emptying apparatus, the containers can be made more cost and volume efficient.
Such bulk containers have been developed which comprise a sleeve, effectively forming the sidewalls of the container, which are sandwiched between a pair of pallets that form the top and bottom of the container. Such a container (as shown in
These containers have good compressive strength in the vertical direction as the containers themselves must be capable of being stacked. Generally, this strength not only comes from the sidewall structure but usually involves the manner by which the top and bottom pallets constrain the edges of the sidewalls. However, because of the foldable nature of the sidewalls, these containers can be difficult to empty since once the top is removed, lateral forces on the walls can cause them to fold readily out of shape, making emptying by tipping or inversion problematic.
SUMMARY OF THE INVENTIONA funnel cap is provided which is configured to replace the cover of the container, thereby retaining any structural integrity afforded by the cover. The funnel cap includes a selectively operable valve. The funnel cap operates in conjunction with a platen which is used to initially support the container in its upright position. The funnel cap and platen are movable away from one another to enable containers to be inserted or removed therefrom. The funnel cap and platen are movable toward one another to enable a container to be engaged and retained therein. The funnel cap and platen exert sufficient force on the container such that during lift and rotation of the container, it will not fall out. Once inverted, the contents of the container will have been gravitationally fed into the funnel. The valve in the funnel may then be selectively operated to dispense discreet quantities of flowable material. In general, by providing the dispensing mechanism in association with the emptying apparatus, the containers can be made more cost and volume efficient.
According to one aspect of the invention, there is provided apparatus for dispensing of flowable material from bulk containers, the containers having sidewalls disposed between a lower pallet and a cover, comprising:
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- a container press, comprising: a platen on which the lower pallet of the container is positionable; a funnel cap adapted to replace the cover of the container; a valve in the funnel cap; and translation means for permitting relative movement of the funnel cap towards and away from the platen; and
- rotation means for rotating said container press about a substantially horizontal axis.
Preferably, the apparatus includes a lift mechanism for raising and lowering the container press.
According to another aspect of the invention, there is provided a method of controllably dispensing flowable product from a bulk container of the type having sidewalls disposed between a lower pallet and a removable cover, comprising the steps of:
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- providing a funnel cap configured similarly to the cover so as to be a replacement therefor, said funnel cap having a selectively operatable valve therein;
- providing a platen generally opposing said funnel cap;
- placing the container on a platen;
- moving the funnel cap relative to the platen to engage the upper edges of the sidewalls of the container within the funnel cap;
- exerting a predetermined pressure on the container by said platen and funnel cap which will be sufficient to prevent the container from falling out from between said platen and funnel cap when rotated;
- rotating said platen and funnel cap to invert the container and permit the contents of the container to flow into the funnel cap;
- operating said valve to dispense an amount of flowable product.
These and other features of the invention will become apparent from the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to
The dispensing system 10 is shown in
The funnel cap 16 contains an angled (preferably about 35°) hopper-style funnel 36, typically made of cut & weld aluminum sheet, and a valve system 38 at its apex. The valve is normally in its “closed” position. The valve may be of the iris-type and may include flow monitoring sensors or meters for accurate dispensing of discreet amounts of the flowable material. Preferably, the valve is “soft” on edges, so as not to crush the product when the valves is closed to interrupt the flow. The valve system 38 may be manually operated or automatically controlled.
Like the platen 14, the funnel cap 16 is configured to accommodate the sleeve's upper edge 23 (see
The funnel cap 16 is mounted within the funnel cap support 40 which is mounted on central arm 42 of the container press 12 (as seen best in
The central arm 42 is rotatable with respect to the remainder of the dispensing system's support 50 to enable the container to be inverted once clamped between the funnel cap 16 and the lower platen 14. The support 50 may be of any suitable type which can function to lift and rotate the central arm 42, and hence the container press 12. In the embodiment shown in
The dispensing operation is shown generally in FIGS. 4 to 6. Incoming, loaded containers 20 are fork-lifted to the product system area and the container 20 is placed onto the lower platen 14. Bands 28, if provided, are cut and the top pallet 24 is removed (although this step may be performed prior to placing the container 20 on the platen 14).
The funnel cap support 40 and the funnel cap 36 in this case are slidable vertically along the central arm 42 and can be lowered to engage the sleeve 22. The descending movement is power-assisted, and may be automatically limited at a predetermined level of compression (grip) of the sleeve.
At this point, optional side supports (not shown) may be mounted around the sleeve 22 and between the lower platen 14 and funnel cap support 40, to counter the side-wall effect of the moving product during the rotation phase.
Depending on the height at which the container press 12 is disposed when the container 20 is vertically “clam-shelled” between the funnel cap 36 and the lower platen 14, it may be necessary to operate the elevator 56 to lift the container press 12 to a safe height off the floor. The “clamped” container 20 may then be rotated around a horizontal axis H through 180 degrees, as seen in
The rotational movement continues until the funnel cap 16 side reaches the lowest point, as seen in
The funnel 36 and the valve system 38 are by now loaded with product and the valve 38 itself can be opened to the desired extent, to start releasing product gravitationally. A proper conveyor system or recipient vessel is obviously placed under the funnel cap 16 at this point.
The flow of product can be interrupted and resumed at any time through operation of the valve 38. The valve actuator may be manual, or could be also powered.
Once the container 20 is empty, the container press 12 can be rotated by means of the rotation mechanism 58 back to its initial upright position while the elevator 56 descends to its initial level, if required. The funnel cap support 40 is moved upward and the container sleeve and bottom pallet assembly is now removed from the platen 14. The optional side supports are also removed or retracted, if installed in the first place. The top and bottom pallets 24,26 and the folded sleeve 22 can be stored for the return trip.
As indicated above, the lift/rotation portion of the dispensing system design may vary. The system shown in
A second embodiment of the dispensing system 110 is illustrated in
Returning to
This dispensing system arrangement 110, shown in operation in
Should the height at which the container 20 was originally placed be insufficient to permit proper clearance from the floor during rotation, or if desired, the container 20 may then be lifted by operating elevator 156 as shown in
The operation has been described sequentially to facilitate explanation. However, it is contemplated that the lift and rotation movements could be effected simultaneously and in various combinations to optimize positioning time.
While the foregoing description and referenced drawings have been framed in terms of emptying containers comprising a foldable sleeve arranged between a pair of pallets, the dispensing system should work equally as well with other container systems having a removable lid such as Ropak™ and Linpac™ brand containers and including disposable containers.
While there has been shown and described herein a dispensing system and method for controlled emptying of returnable containers, it will be appreciated that various modifications and or substitutions may be made thereto without departing from the spirit and scope of the invention.
Claims
1. An apparatus for dispensing of flowable material from bulk containers, the containers having sidewalls disposed between a lower pallet and a cover, comprising:
- a container press, comprising: a platen on which the lower pallet of the container is positionable; a funnel cap adapted to replace the cover of the container; a valve in the funnel cap; and translation means for permitting relative movement of the funnel cap towards and away from the platen; and
- rotation means for rotating said container press about a substantially horizontal axis.
2. An apparatus as claimed in claim 1, further comprising lift means for raising and lowering said container press.
3. An apparatus as claimed in claim 2, including a vertical mast along which said container press is raisable and lowerable by said lift means.
4. An apparatus as claimed in claim 3, further including rotator means for rotating said vertical mast about its vertical axis.
5. An apparatus as claimed in claim 1, wherein said platen is configured to accommodate a range of pallet configurations.
6. An apparatus as claimed in claim 5, wherein said platen includes means cooperative with the lower pallet of the container to resist relative lateral movement therebetween.
7. An apparatus as claimed in claim 1, wherein said funnel cap comprises a hopper-style funnel.
8. An apparatus as claimed in claim 1, wherein said funnel cap is adapted to accommodate upper edges of said sidewalls.
9. An apparatus as claimed in claim 8, wherein a channel is provided in said funnel cap which is engageable with the upper edges of said sidewalls.
10. An apparatus as claimed in claim 1, wherein an adaptor cooperates with said funnel cap to permit said funnel cap to replace the cover of various sizes of containers.
11. An apparatus as claimed in claim 1, further comprising means for automatically limiting the relative movement of the funnel cap towards the platen at a predetermined level of compression.
12. An apparatus as claimed in claim 1, wherein said container press further includes lateral side supports for supporting the sides of the container.
13. An apparatus as claimed in claim 1, further comprising a base which is affixable to a floor.
14. An apparatus as claimed in claim 1, further comprising a base from which a plurality of outrigger arms extend for increased stability.
15. An apparatus as claimed in claim 1, further comprising means for monitoring the amount of flowable material being dispensed.
16. A method of controllably dispensing flowable product from a bulk container of the type having sidewalls disposed between a lower pallet and a removable cover, comprising the steps of:
- providing a funnel cap configured similarly to the cover so as to be a replacement therefor, said funnel cap having a selectively operatable valve therein;
- providing a platen generally opposing said funnel cap;
- placing the container on a platen;
- moving the funnel cap relative to the platen to engage the upper edges of the sidewalls of the container within the funnel cap;
- exerting a predetermined pressure on the container by said platen and funnel cap which will be sufficient to prevent the container from falling out from between said platen and funnel cap when rotated;
- rotating said platen and funnel cap to invert the container and permit the contents of the container to flow into the funnel cap;
- operating said valve to dispense an amount of flowable product.
17. A method as claimed in claim 16, further comprising the step of raising the container within the platen and funnel cap prior to or while inverting the container.
18. A method as claimed in claim 16, further comprising the step of raising or lowering the container within the platen and funnel cap after or while inverting the container to adjust the height at which the flowable product is dispensed.
19. A method as claimed in claim 16, further comprising the step of rotating the container, platen and funnel cap about a vertical axis.
20. A method as claimed in claim 16, further comprising the step of supporting the sidewalls of the container at least during inversion of the container.
21. A method as claimed in claim 16, wherein after a desired amount or all of the flowable product has been dispensed,
- rotating said platen and funnel cap to upright the container,
- moving the funnel cap relatively away from the platen to permit the sidewalls of the container and the pallet to be removed from therebetween.
Type: Application
Filed: Nov 3, 2004
Publication Date: Jun 2, 2005
Patent Grant number: 6962271
Applicant: Sertapak, Inc. (Woodstock)
Inventor: Kenneth Gregson (Loveland, OH)
Application Number: 10/979,753